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Books by MMTI members and
associates (not rated)
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Lean
Logistics: The nuts and bolts of delivery materials and goods, Michel
Baudin, Productivity Press,
New York, NY, ISBN 1-56327-296-2 (2005)
- Are your warehouses full while
production is stopped by shortages?
- Do you know what you have,
and when the next replenishments will come?
- Do your customers complain
of long lead times and late deliveries?
- Does the volume of your
logistics activities vary erratically?
This books addresses these
issues. It covers both the physical infrastructure of lean
logistics and the information flows that compose its nervous
system, as well as innovative approaches to supplier relations.
Find out how to avoid shortages while maintaining low
inventories and take advantage of the increased capacity and
flexibility generated through lean manufacturing.
This book picks up where
Lean Assembly left off -- it
clearly discusses and illustrates how to deliver parts
efficiently to assemblers, and the correct process for finished
goods after completion. Lean Logistics completely covers
manufacturing logistics, including its interaction with
production control. -
Lean
Assembly: The nuts and bolts of making assembly operations flow,
Michel
Baudin, Productivity Press,
New York, NY, ISBN 1-56327-263-6 (2002)
Lean Assembly is a guided tour of lean
manufacturing techniques applied to existing or newly designed assembly
facilities. The author aims to illustrate the improvements and provide
factory personnel engaged in lean initiatives with ideas, solutions, and
analytical tools.
Lean Assembly differs from most other
books on lean manufacturing in that it focuses on technical content as a
driver for implementation methods. The emphasis is on exactly what should
be done. This book should be the "dog-eared" and
"penciled-in" resource on every assembly engineer's desk.
"This book is a welcome and much
needed study of many cases and techniques for assembly line design."
(Target magazine, 3rd Quarter 2003)
"Critical concepts such as takt
time, line balancing and assembly cells are presented in great
detail... virtually every page contains clear drawings or
photographs to help the reader understand the concepts. While
many books on lean manufacturing talk in generalities, this one
is rich in details and excellent examples." (Quality Progress,
November 2003)
"A thoughtful book that Baudin
describes as being “about what should be done rather than how to
do it.” The book is prescriptive, yet it is not a step-by-step
approach to improving assembly operations. Through text,
diagrams, drawings, photographs, and graphs, Baudin lays out
various aspects of lean production (visual management; one-piece
flow) but all in the context of assembly operations. While not
all of these examples are automotive-specific, regardless of the
industry, the approach transcends particulars.
[...] Lean Assembly ought to be a book that each executive
studies with some high level of seriousness because Baudin
examines assembly from a variety of perspectives, from line
layout to final inspection, to the required data collection
methodologies in between. Much of this is common sense. Yet even
when something is sensible, it is sometimes hard to implement.
[...] Understanding and implementing some of Baudin’s
prescriptions will be time well spent. But remember: You have to
do it." (Gary Vasilash, in
Automotive Design and Production, March 2003)
When you invest millions on new systems
you don't want yesterday's solutions. You need a global view of end-to-end
material, information, and financial flows. Managers today have the same
concerns managers had last year, 10 years ago, or 50 years ago: products,
markets, people and skills operations, and finance. New supply chain
management processes give managers a hierarchy to the tasks they must
perform to deal with these issues. Containing hundreds of tips and
insights, the Handbook of Supply Chain Management describes the evolution
of supply chain management. It explores how the techniques now popular in
strategic planning and operations improvement will find new applications
in managing supply chains. The author emphasizes changing supply chains
rather than merely maintaining them. He uses case studies to illustrate
the application of these techniques.
In the supply chain world, managers face
the choice between the "business as usual" single company approach or
exploiting innovations in supply chain and project management. As the
first book to take a project management approach to supply chain
management, it explains a four-stage progression toward world class
supply chain project management. This easy-to-use guide will boost
readers' efforts to implement supply chain improvement by detailing the
keys to a supply chain strategy, slashing costs, and generating more
revenue.
The author provides a template of the
stages encountered when moving to competitive supply chains, delineates
the project management processes that organizations must implement if
they are to advance from one stage to the next, and describes best
practices on how to get there. He supplies structured approaches for
project management and supply chain analysis and documentation , and
illustrates the concepts with examples from the trenches.
In 1991, the original edition of this
book became an instant hit as the leading guide to reducing product
development cycle time. The expanded set of tools in this new edition
meets the needs of today's more demanding times. The book's premise
remains solid: time is worth money, and if you quantify this value you can
buy time wisely, often to enormous advantage. Rather than pursing
development speed at any price, the authors emphasize subjecting
time-to-market decisions to the same hard-nosed business logic used for
other management decision. Developing Products in Half the Time, 2/E is
unique in providing tools for trading off schedule against other business
objectives. It integrates powerful methods to manage risk and use
resources effectively with proven techniques to accelerate product
development. Smith and Reinertsen discuss hundreds of practical tools for
reducing cycle time, describing each one's application and limitations.
Countless examples including Black & Decker, Hewlett-Packard, Honda,
Motorola, and other illustrate how real companies use the tools. With six
more years of implementation experience and responses from readers of the
original 60,000 copies, the authors have sharpened the original tools and
added new ones.
Proactive Risk Management provides
product development teams and managers with a step-by-step process for
managing innovation risk in an effective cross-functional manner. In
addition to providing a formula, this book illuminates the rationale of
managing project risks allowing project and product development managers
to successfully adapt the process to their organizations and projects.
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General on JIT/lean
production/lean manufacturing
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The
new manufacturing challenge, Kiyoshi Suzaki, The Free Press,
New York, NY, ISBN 0-02-932040-2 (1987)
Suzaki's book, like the other
introductory texts, describes the operations of factories practicing
JIT/lean production, but not how to convert a traditional plant.
It describes the destination but not the way to get there. This
is appropriate for readers who are new to the subject, and Suzaki
writes well enough to retain a manager's attention during air
travel.
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KANBAN
Just-In-Time at Toyota, Edited by JMA, translated by David
Lu, Productivity Press, Inc., Cambridge, MA, ISBN 0-915299-48-8
(1985)
This book covers much of
the same ground as Suzaki's and is a suitable alternative. It
does, however, suffer from two drawbacks. First, having been
written by a group, it lacks a strong authorial voice. Second,
it is a translation, and the English is in places awkward and
unclear. As a result, it is both less entertaining and more difficult
to understand.
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Zero
Inventories, Robert W. Hall, Dow Jones Irwin, Homewood, IL,
ISBN 0-870940461-4 (1983)
While the above two books
were written by consultants, this one is the work of a professor
of Operations Management at Indiana University. Hall's book is
longer, more detailed, and more technical. You would not typically
read it cover to cover but rather use it as a reference. The
title is a bit misleading: JIT/lean production is done with low
inventories, but the level is not zero.
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On implementation
strategy and tactics
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In the 2/92 issue of the Harvard
Business Review, Robert Shaffer wrote an article entitled "Successful
change programs begin with results." This title is a thumbnail
summary of the author's philosophy. In the book, he explains the
difference between results-driven and activity-centered programs, the role
of pilot projects and the means of expanding the scope of change to
encompass the entire organization.
The only reason not to give this book
the maximum four-wrench rating is that it is not specifically about lean
manufacturing. In addition, while his criticism of activity-centered
programs is valid, there are parts of lean manufacturing, such as 5S and
TPM, that cannot be implemented any other way.
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The
Kaizen Blitz, Anthony Laraia et al., John Wiley & Sons, New
York, NY,
ISBN 0-471-24648-4 (1999)
This book presents the "Kaizen
Blitz" -- also known as "Kaizen event," "Accelerated
Improvement Workshop" and other names -- as created around 1994 by a
group of executives from American manufacturing companies that were
frustrated with the slow pace of progress achieved through small group
activity by team of volunteer operators. It goes on to give an informative
account of how to set up and run a Kaizen Blitz, based on case studies
from such companies as Wiremold and Lantech.
It has two shortcomings:
- The Kaizen event is presented as the
implementation tool, to the exclusion of any other approach. This is
widely held but mistaken belief, and it should be presented as one
tool in a box that contains many others. There is more to implementing
lean manufacturing than running hundreds of Kaizen events.
- There is no reference in the book to
the experience of Toyota's "jishuken" (autonomous study
groups), developed since 1976 and looking very much like Kaizen
events. Jishuken is the term used to described rapid improvement
workshops at Toyota in the US and in the UK. All the documents in
English about Jishuken are from the UK.
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The
Idea Generator, Bunji Tozawa & Norman Bodek., PCS Press,
Vancouver, WA,
ISBN 0-9712436-9-7 (2001)
Bunji Tozawa has written a two-volume
series about Kaizen, which represent the generally accepted meaning of the
term in Japanese. "Kaizen Blitz," by contrast, in a
Japanese-German oxymoron meaning literally "lightning strike of
continuous improvement." As Tozawa and Bodek use the term, Kaizen
designates small changes in work methods implemented by the people who do
the work. It about things like wrapping foil around the feet of a
welding fixture to make it easier to clean, not about cellularizing a
process. Kaizen in fact addresses the kind of issues that are likely to be
ignored in the rush of a Kaizen Blitz.
Where the authors perhaps err is in
asserting that Kaizen is "quick and easy." They convey the
impression that all you have to do is open the flood gates to employees'
creativity. The creativity is there, but putting it to good use, further
growing it in the process, and sustaining that effort year after year is
anything but easy.
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Kaizen,
Masaaki Imai, McGraw-Hill, New York, NY, ISBN 0-07-554332-X,
(1986)
This book is mostly of historical
interest. It introduced the word "kaizen" into the English
language, with the meaning of continuous, incremental improvement, but it
is otherwise dated both in content and in tone, systematically opposing
Japanese to "Westerners," with the universal conclusion that
everything Japanese is better.
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Gemba
Kaizen,
Masaaki Imai, McGraw-Hill, New York, NY, ISBN 0--07-031446-2, (1997)
As the title indicates this book is
more focused on the shop floor. Half the book is in the form of case
studies, many of which are from American and European companies. The
nationalistic undertone of the previous book is gone. Whether this is due
to the author having gained more perspective in 11 years or to
the dismal performance of the Japanese industry in the 90's may never be
known, but it is in any case a welcome development.
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On manufacturing cells
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One-piece
flow, Cell Design for Transforming the Production Process,
Kenichi Sekine, Productivity Press, Portland, OR, ISBN 0-915299-33-X
This is a book on an essential
topic for JIT/lean production written for American audiences
by an experienced Japanese consultant, and loaded with case studies
from industries ranging from sheet metal to fishing rods. So
it is a priori a prime candidate for a four-wrench rating. While
it is a very useful book, it doesn't quite make that grade.
The first part of the book, on "Basics" is substantive
but awkwardly structured. One key concept is "process razing,"
but it is referred to forty pages before it is defined, and then
the expression "process razing" is used in its own
definition. If you can ignore this type of issues, you will find
practical ideas and analytical tools sprinkled throughout. The
second part of the book is a collection of in-depth case studies
that can be read independently and provide not only technical
but project management insights. In our own experience of implementing
one-piece flow through cells and quick setups, several issues
repeatedly come up that are not covered in this book:
- What to do with operators
who are removed from a line as a result of improving productivity.
- How to integrate deburring,
degreasing, and other secondary operations into U-shaped cells.
- How to deal with shared
resources such as heat treatment or painting facilities.
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On setup time reduction
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On organization and people
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Team Toyota: Transplanting the Toyota
culture to the Camry plant in Kentucky, Terry L. Besser, SUNY, New York, ISBN 0-7914-3145-2,
(1996)
Skip chapters 1 and 2, unless
you want to check out the author's background and his methodology.
If you are willing to trust him, start from Chapter 3 and get
not only details about shift patterns and team structure but
also the results of interviews of employees on their experience
of the Toyota production system day after day.
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Work,
Mobility, and Participation, A Comparative Study of American
and Japanese Industry, Robert E. Cole, University of California
Press, Berkeley, CA, ISBN 0-520-04204-2, (1979)
Although based on research
conducted in the 1970's, this book remains the most valuable
reference we have found on personnel practices within the Toyota
production system. It contains a detailed analysis of operator
evaluation and career pathing at Toyota Auto Body, along with
case studies of improvement projects. What keeps you turning
the pages in Cole's book is his sober, critical look at the subject,
which is a welcome relief from the cheerleading tone of most
business bestsellers.
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- Just
another car factory, James Rhinehart et al., Cornell University
Press, Ithaca, NY, ISBN 0-8014-8407-3, (1997)
This book criticizes lean
production at CAMI as a major disappointment to the work force
and is a useful cautionary tale for implementers of lean production.
Based on this book, the major problem with lean production at
CAMI appears to be that it did not live up to its advance billing.
The initial training generated expectations of work life that
the experience of assembling cars could not fulfill, leading
the workers to the conclusion that CAMI was "just another
car factory."
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Reengineering
the corporation, M. Hammer & J. Champy, Harper Business,
New York, NY, ISBN 0-88730-640-3, (1993)
Having sold over 6 million
copies, this book needs no introduction. And it's not about JIT/lean
production, so why recommend it? Although the authors do not
acknowledge it, business process reengineering looks like JIT/lean
production applied to white collar activities. This and the influence
of this book on American business today are strong enough reasons
to make it a must-read. In addition, for a business best seller,
it is unusually clear-headed, concise and to the point. This
being said, for balance's sake, let us list a few shortcomings:
- The authors did not anticipate
how extensively "vocabulary engineering" -- that is,
attaching new labels to old structures, would thwart implementation
of their ideas. Executives have titles like "VP of order
fulfillment" and managers refer to themselves as "process
owners," but behind this facade, it is largely business
as usual.
- The "process"
model does not do justice to the full complexity of business
organization. Not everything can or should be organized as a
process. The contrast between functional departments and processes
is relevant and useful, but not sufficient.
- Toyota, the company that
created JIT/lean production, is not systematically organized
around business processes, but with functional departments supplemented
by cross-functional committees at the top management level and
a variety of structures at lower levels.
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Strategic
Compensation, Joseph J. Martocchio, Prentice Hall/Pearson Education,
Upper Saddle River, NJ, ISBN 0-13-028030-5 (2001)
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On 5S, TPM, and
Visual Management
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Training
for TPM, Edited by Nachi-Fujikoshi Corporation, Productivity
Press, Cambridge, MA, ISBN 0-915299-34-8 (1990)
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On quality
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- "Pokayoke," or
mistake-proofing production processes through small equipment
retrofits, is the most innovative concept in quality of the past
20 years. Where, as is the case is most mechanical and electronics
assembly operations, most defects are caused by human error,
pokayoke can get your reject rate from 0.5% to 20 ppm. This book
contains little theory but 240 actual examples from a variety
of Japanese factories. It's not a book you read cover to cover.
You can search is multiple indexes for an example relevant to
a problem you are trying to solve, or you pick it up when you
have a few minutes of spare time and read through a few examples.
Its only limitation is a focus on conventional equipment. There
is nothing about mistake-proofing computer-controlled systems.
(See "The
design of everyday things" below.)
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Shigeo Shingo will be remembered as the
inventor both of quick changeover methods (SMED) and mistake-proofing (Poka-Yoke).
This book is useful mostly for the examples of Poka-Yoke. It also contains
a classification of inspection activities in which the best kind is called
"source inspection," and is synonymous with mistake-proofing. It
starts in a more philosophical tone, with comments that are guaranteed to
make statistically trained quality professionals bristle. Shingo clearly
thinks that mistake-proofing is superior to statistical methods, but fails
to specify the conditions for this to be true.
Our view is that the applicable tools
for quality improvement depend on what the quality problems are. If they
are primarily human error, then mistake-proofing will work. On the other
hand, if they are due to insufficient process capabilities, then process
characterization through statistical design of experiments will be much
more help than mistake-proofing.
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- The only reason this book
does not rate four wrenches is that it isn't directly about manufacturing.
Many of the ideas in it, however, are directly applicable on
the shop floor. It is about how to design objects so that people
can use them effectively with little or no training. Norman's
objects of study range from door knobs and faucets to computer
screens and control rooms in nuclear power plants. This book
is based on experimentation, but infers from the results general
principles that can be applied in a variety of domains, including
the mistake-proofing of operator interfaces to automatic systems
on the shop floor. This makes it complementary to
Poka-Yoke:
Improving product quality by preventing defects (See above).
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Although the title does not say so, this book is about the Taguchi
methods for statistical design of experiments, and it is in fact the best
book we have found on the subject. It focuses on tools and techniques and
is free of the Confucian mumbo-jumbo about the good of society at large
that encumbers other books about these techniques.
As presented by Phadke, the methods are a subset of statistical design
of experiments, refined and focused on a particular kind of objective
functions called "signal-to-noise ratios." The approach is to
make the processes first precise, and then accurate.
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On history
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- A fascinating read about
a man who has been thoroughly and unfairly vilified for 80 years.
Taylor did not invent the assembly line, many of his ideas were
abandoned, and others altered beyond recognition. But Taylor
was an engineers' engineer, fascinated since childhood by how
things are made, who not only founded the discipline of industrial
engineering but also invented high-speed steel tooling.
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(Michel Baudin's rave review of this
book is on the Amazon site)
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- Isaac Newton was history's
first industrial engineer! The only reason this otherwise excellent
biography doesn't rate more than two wrenches is that most of
the book is devoted to what Newton is better known for. Chapter
11 describes how, in 1696, after 30 years in academia, Newton
took the job of "Warden of the London mint" and proceeded
to improve the efficiency of its operations through time-and-motion
studies (p. 261), a full 200 years before Taylor. Since it is
doubtful that usable stopwatches existed before 1696, it is unlikely
that anyone had tried before.
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While this is an excellent book, it
only rates two wrenches because it's not about manufacturing. The kind of
risk Bernstein is mostly interested in is not that of making or failing to
detect bad parts but that of misreading the stock market. A manufacturing
professional might want to skip the later part of the book and focus on
the accounts of the origins of statistics in population studies for the
purpose of taxation and insurance underwriting, of probability theory in
gambling, and how the two came together to produce the tools we use to
manage all sorts of risks.
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On performance
metrics and management accounting for lean manufacturing
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This is a collection of case studies of
Shingo Prize winners, not all of which are about the impact of lean
manufacturing. Two of them, Wilson Sporting Goods and Gates Rubber are in
fact discussions of TQM instead. The case studies cover both the changes
made to the services provided by management accounting and improvements
made to the internal operations of the accounting department.
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Management
accounting, Anthony A.Atkinson et al., Prentice Hall, Upper
Saddle River, New Jersey, ISBN 0-13-016809-2 (1995)
This is a college textbook, printed in
large type, with many color photographs, key term lists, review questions
and exercises with each chapter. It is useful either if you want to become
a professional management accountant or as a reference on the subject.
Oddly, it does not contain an intelligible definition of the word
"cost."
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Keeping
score, Mark Graham Brown, Amacom, NY, ISBN 0-8144-0327-1 (1996)
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This is a collection of articles,
dominated by the theme of Activity-Based Costing. Two of the articles,
however, relate to lean manufacturing. The main one is "Cost
Accounting and Cost Management in a JIT Environment," by George
Foster and Charles T. Horngren on pp. 34-43. It makes the case that lean
manufacturing simplifies cost accounting, and describes backflush costing
as an approach to product costing that simplifies bookkeeping and works in
a quick turnaround environment. The other article, by editor Mark Young,
on pp. 311-322, is entitled "A framework for successful adoption and
performance of Japanese manufacturing practices in the United
States." First published in 1992, it is a bit dated, and is not
specifically about the financial side of lean manufacturing.
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The
visible hand, Alfred D. Chandler, Harvard University Press, ISBN
0-674-94052-0 (1977)
Although the way American industry has
moved since the publication of this book is not what the author anticipated,
it is a detailed and vivid history of the emergence of current management
accounting practices in response to the different needs of small textile mills
in the 1840's, railroads in the second half of the 19th century, and
diversified, vertically integrated enterprises in the 20th. Where Chandler's
story stops, he sees the "visible hand" of management continuing to
replace the invisible hand of the markets in allocating resources and
directing industry. The 25 years since then, however, have seen a move away
from vertical integration and a renewed reliance on market mechanisms.
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This book starts out covering the same
historical ground as "The visible hand"
with fewer details, but takes the story 10 years further, into the 1980's,
when, according to the authors, the management accounting systems that had
served industry well for 60 years lost their relevance.
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On product
development
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This is an excellent book, and the only reason not to give it the
maximum four wrenches is that it is not particularly about lean
production.
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MMTI author |
This is not a treatise on how to develop products but a journalist's
account of the development of the MV-8000 computer at Data General in
1980. The company had been caught by surprise by DEC's introduction of the
VAX in 1978 and needed a response. The book has all the elements of a
thriller: an inept corporate bureaucracy squandering millions on a
luxurious research facility for no return, while a small band of rebels in
the cellar of an old building succeed against the odds in developing the
product that gave the company a new lease on life.
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Car,
Mary Walton, W W Norton & Co; ISBN: 0393040801
(June 1997)
Like, "The soul of a new machine," this is a product
development case study - if the 1996 Taurus at Ford - by a journalist who
was invited to follow it from start to finish. The most interesting aspect
of this case is that, while the development project was technically
successful, the resulting product did not keep its promises in the
market.
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Reviewed by Preston Smith: "A classic account of how time is used
to gain competitive advantage in business today, in product development as
well as in other areas."
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Click
here for
Preston Smith's review of this book.
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Reviewed by Preston Smith: "Rapid development requires a well
articulated product strategy as well as product line and technology plans.
For additional coverage on these topics, see Chapters 2-4 of Wheelwright
and Clark. However, note that it has little focus on development
speed."
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Reviewed by Preston Smith: "Includes a thorough treatment of QFD,
but being a mainline book on the subject, it is not oriented towards
speed."
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Reviewed by Preston Smith: "Reaching agreement on a specification
by several parties is essentially a process of negotiation, and skill in
negotiating win-win agreements speeds up the process. Fisher and Ury's
supports our suggestion of concentrating on benefits. These authors
emphasize that it is more productive to understand each party's underlying
interests than just to state positions, which then tend to become
inflexible."
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Reviewed by Preston Smith: "An excellent, compact book on this
important subject. It stems from the customer visit training he has
conducted at Hewlett Packard. However, McQuarrie has a traditional market
research tendency that needs to be turbocharged a bit to accelerate the
process."
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Logistics and Supply
Chain Management
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When you invest millions on new systems
you don't want yesterday's solutions. You need a global view of end-to-end
material, information, and financial flows. Managers today have the same
concerns managers had last year, 10 years ago, or 50 years ago: products,
markets, people and skills operations, and finance. New supply chain
management processes give managers a hierarchy to the tasks they must
perform to deal with these issues. Containing hundreds of tips and
insights, the Handbook of Supply Chain Management describes the evolution
of supply chain management. It explores how the techniques now popular in
strategic planning and operations improvement will find new applications
in managing supply chains. The author emphasizes changing supply chains
rather than merely maintaining them. He uses case studies to illustrate
the application of these techniques.
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MMTI author
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This is a well focused, well written
book that we have found a source of useful ideas on analyzing warehouse
operations and on designing warehouses. Our only reservation about it is
that it does not specifically address the lean manufacturing approach to
the subject. For example, there is no discussion of milk runs, shop floor
supermarkets, or visible controls.
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This book expands on Frazelle's World
Class Warehousing book, still without addressing the lean approach in any
depth. Unlike Frazelle's previous book, this one shows signs of having
been produced in haste, including the following:
- Examples lifted verbatim from
"World Class Warehousing" without attribution.
- There are contradictions, such as
stating in one chapter that inventory carrying cost dominate.
logistics costs, and awarding the same distinction to transportation
costs in another.
- Some illustrations have captions
that are too small to read.
- Numerous affirmations of the
author's religious beliefs, that are irrelevant to logistics.
This being said, we have still found it
a source of ideas.
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This is the only book in this aisle that
explicitly refers to lean anything in its title. As the subtitle suggests,
however, the focus of the content is on cost management through collaborative
supplier-customer relations, involving in particular target and kaizen
costing. It includes case studies of nine Japanese companies. Unlike most
other books in this list, it includes a bibliography.
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Logistics,
David J. Bloomberg et al., Prentice Hall, Upper Saddle River, NJ ISBN 0-13-010194-X
(2002)
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Supply
Chain Optimization, Charles C. Poirier & Stephen E. Reiter, Berret
Kohler Publishers, San Francisco, CA, ISBN 1-881052-93-1 (1996)
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